-

.:

Introduction
Manufacturing Technolodes Cardedwebs
Airlaidwebs
Needle punching

Spunlacing
Resin bonding

Spinbonding Stitch bonding Film to network structures

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11-2 AberWeb and Related Fabrics

Woven, Knit Fabric Characteristics

Strength Flexibility Shearability,drape, conformability Fullness, hand, resilience Dimensional stability

Fiber Fiber

Yarn

Fabric(Sheet1

Fabric (Sheet)

Nonwoven Fabrics Sheet or web structures made by bonding and/or interlocking fibers, yams, or filaments by mechanical, thermal, chemical or solvent means.

RberWeb and Related Fabrics 11-3

Classes of Nonwoven Materials

Fiber-web structures (Homogeneous) Multiplex structures (Laminates,Composites) Netlike structures (Fibrilated films, Formed webs)

1 1 4 AberWebandRebtedFabflcs

i
c

RberWeb and Related Fabrics 11-5

Major Markets ($MM)

cov stk (bb diap) (other)

1974 75 35 33 32 65 35

%na.

1984 215 65 160 145 115 150 100

%ma* 9 9

1990 360 285 285

surgical packs gowns, acc. wipes, towels interlinings coat/lam. substr. geotex./roofing filter media

10 12 7
11

17 13 12 13 13
8

245

bedd/h.f. acc.
--._

durable paper disp. apparel carpet comp.

source: S t a (1984) ~

11-6 RberWeb and Related Fabrics

Table 1 1-1 US Consumption of Nonwovens

1970
Dry Staple

1977 178

1982 187 93 45 65 390

1984 207 118

1990a 230 214

100

Spunbonded
Wet Laid
Otherb Total

21
14 5 140

48
32 27

50
90 465

72
159

285

675

'Estimated bIncludes air laid pulp, spunlaced, melt blown, composite and porous film. Source: John R Starr, Inc.

RberWeb and RelatedFabrlcs 11-7

E
H -

I
I

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11-8 RberWeb and Related Fabrfcs

Typical End Use Areas

Apparel Interfacings Maps Mattress Covers Packaging Quilts Road and Soil Stabilization Safety Garments
Sanitary Napkins

Art Canvases
Auto Components Battery Separators Bedding Blankets
Book Covers

Building Materials Carpet Components Coated Fabrics Diapers Draperies Electrical Insulation

Sheets and Pillowcases

Shoe Components

Surgical Packs and Gowns

Table Covers Tea Bags Towels Undergarments

Filters Fumiture
Luggage

Wall Coverings
Wipes

AberWeb and Related Fubdcs 11-9

Other Typical End Use Applications For Nonwovens

Artificial Leather Bedspreads Bibs Cable Wrappings Caps Casket Liners Cheese Wrap Clean Room Apparel Clothing Insulation Coveralls Examination Gowns Incontinent Pads Ironing Board Pads Labels Lampshades Parachutes Pennants Robes Scouring Pads Signs Sleeping Bag Liners Swimwear TailorsPatterns Tarpaulins Tents Wash Cloths Window Shades

Kites
Lab Coats

11-10 Fiberweband Related Fabrlcs

F
Cotton

m
Cellulosics (Rayon, Acetate) Wood Pulp Polyamides (Nylons) Polyesters Polypropylene Acrylics Glass etc.

Processes Dry Formed: Carded, Air-Laid

Spunbonded Spunlaced (?) Wet-Laid Composite FilmExtrusion

Needle Punched (?)

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RberWeband Related Fabrlcs 11-11

Elements Of Manufacturing Technologies

(Using Staple Fibers)

Preparation

W e b Formation

- Carding systems
- Gamett systems

-Air-Laid systems
Bonding - Mechanical - Chemical -Thermal/Sonic

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t I.
11-12 F W e b and Related Fabdcs

a. feed lattice b. squeeze zone c. feed roll d. lickeridtakerin e. first or breaker cylinder f. intermediate doffer or transfer roll g. cleaner roll

h. angle roller i. maincylinder k. worker 1. stripper m. fancyroll n. doffer

0.

vibrating comb

AberWeband Related F a

11-13

Figure 1 1-1 Carded Web Flow

' 3
1.Cd 2.cardweb

3. Transport lamce ~~ontinuous~pron

2.cardweb 3.Tlcnsport Lattice

.-.

W e b a n d Related Fakics 11-15

Carded Webs 0.1 - 0.3 (oz/yd2) on conventional cards (low mass, bulk and integrity) up to 3 (oz/yd2) on modem NW cards To Build a Fleece: Layering by tandem cards Parallel Lapping Cross Lapping Productivity up to 2.5 lbdin (MIC)/h.r(conventional card). up to 10 Ibdin (WCYhr (modern NW cards).
Garnet Webs Fleece built by layering Productivity 6 lbdin (MIC)/hr.

Rando-Webber Air-Laid fleece 0.3 - 75 oz/yd2 1/64 i - 4 i thickness n n Productivity 1 - 8 lbdin (M/Cyh,

on
d

Q)

Q)

AberWebandRelatedFabrlcs 11-17

Figure 11-2 Fiberwoven Process

Needle B

i
C

Barbed Needle Engageing Fibers On Being pushed Into Fiber Batt

11-16 FlberWeb and Related Fabrlcs

Factors Influencing Properties Of Needle Punched Fabrics

Structure of web: - (11, X, Random) -Extent of fiber pickup Fiber properties: -Fiber fineness - Coefficient of friction - Length . - Extensibility Web weight (thickness) Web movement Needle penetration Needle punch density

RberWeband RelatedFakics 11-19

pi
Lu

11-20 FlberWebondRelated Fabrlcs

Figure 11-3 Spun Laced Systems

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Rberweb and Related Fabrks 11-21

Resin Bonding
Thermoplastic Fibers (Vinyon, Saran, Cellulose, Acetate, PE, Pet) Thermoplastic and ThermosettingPowders (Acrylic beads, Vinyl beads, Phenolic. . .)

Liauid Binders Aqueous Solution -(PVA, Amylose, Na Alginate, Casein. . .)

Organic Solvent Binders -(N. Rubber & Benzene, PVC & Cyclohex...)

Water Based Emulsions -PVC - PVC Acetate -Polyacrylates -Acrylic Esters - Natural R. Latex -Butadiene Acrylonirtile - . . . Copolymers -Melamine -Melamine-urea -Urea-formaldehyde -Phenol-formaldehyde

Figure 1 1-4 Impregnation Bath Diagram

Web
GI

Web

11-24 W e b and Related FabrlCS

Du Pont spunbonding process illustrating air aspirator and electrostatic repulsion techniques.

4
I

The spin-draw route to spunbonded fabrics showing the optional use of a separate feed of bonding filaments.

RberWebandRektedFaklcs 11-25

A-

BA*--ASheamOfHotAir C.cadAL B.pdymetfeed D conneclorscreen .

T e Manufacture o Melt-Blown SpunbondedTeh f

11-26

Figure 1 1-5 Fibrillates

--

W e b and Related Fabrics 11-27

Figure 1 1-6 Arachne Stitch Bonding

11-28 W e b and Related Fabrlcs

Figure 1 1-7 Arachne Stitch Bonding

AberWebandlFelatedFabrlcs 11-29

11-30 FiberWeb ond Related

Figure 11-8 Malimo Fabric

RberWebandReIatedFabrkX 11-31

Figure 11-9 Wetlaid

Fiber Suspension

Q
Screen

0 C c ] ,
De-watering
Driving

Wet Layed Fibrous Layer

11-32 FlberWeb and Related Fabrics

Flocked Fabrics
Definition Flocked fabrics consist of short fibers bonded to substrate to achieve a decorative or functional effect

Fibers
Natural or man-made, mostly cotton, rayon, nylon, random or precision cut, natural or dyed

--

Rberweb and Related Faklcs 11-33

Flocking Methods
0

Mechanical or beater bar Electrostatic -DC or AC - Downward -Upward Electrostatic and mechanical Giroud process Electrostatic alignment and mechanical insertion Synthetic k flocking
Air turbulence (ttslush molding)

11-34 FlberWeb and Related Fabrlcs

Figure 1 1 10 Electrostatic Flocking: Flocking Down

I
I

RberWebandRektedFabrlcs 11-35

11-36 FlberWeb and Related Fabrlcs

W e b and Related Fabrics 11-37

Bonding Agents Neoprene (obsolete) Self-reactive acrylic emulsions Urethanes Epoxides (for metal substrates)

Substrates Woven fabrics

0

Non wovens Plasticfilm Metal foil

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Leather
Wood

Rubber Paper Glass Three-cimensionh objects

_- . 0

Expanded vinyls

11-38 FiberWebond Related Fabrlcs

Application Of Adhesive
Coating and laminating techniques - Doctor blades (knife coating) - Kiss or transfer rolls -Reverse transfer rolls - Spraying -Extruding -Hot Melt Roller printing techniques Screen printing techniques Finishing Techniaues Dyeing
0

Printing Embossing Shearing

Aberweb and Related Fabrlcs 11-39

Uses
ltuo-Dimensional Draperies
Carpets Wall Paper Velvets Boxes Shoe Uppers Blankets Auto Tops Paint Rollers Tumtable cushions Acoustical Dampening Upholstery Fabrics Floor Tiles Wrapping Paper Crushed Velvets Pocket Books Synthetic Fur Acoustical Wall Panels Auto Window Channels Non-slip Bases Mar-proof Bases Vibration Dampening

Three-Dimensional Hats
Toys

Gloves

YarnS

11-40 W e b and Related Fabdcs

Figure 1 1= 1 1 Tufting: Yarn Flow

iy

\.

'1

Aberweb and Related Fabrlcs 11-41

Figure 11-12 looper

Looper

'U

stage3

L
11-42 FlberWeb and Related Fabrlcs

Needle

YarrJ

Pile

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flberweb and Related Fabrlcs 11-43

Adhesives & Backcoating

Function - Binding Tufts -Prevent Rlling -Attach 2' Backing
Improves -Hand -Tear Strength - Dimensional Stability

.-

Type

Synthetic Lattices (SBR) -Natural Latex (Rubber) - Hot Melts -Ethylene - Vinyl CI

Application -Roller Coater -Froth 24 - 35 odyd2

11-44 FlberWeb and R e l a t e d Fabrics

Attached Cushions
BRes Foam Rubber

Sponge Rubber
Vinyl

FIberWebandRelatedFabrlcs 11-45